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FABRICATION & MANUFACTURING
PORTFOLIOwww.aircorpsaviat ion.com
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O U R C O M PA N Y
36 employeesHeadquartered in Bemidji, Minnesota
SHOP HIGHLIGHTS• 5,200 sq. ft. machine shop
• 9,500 sq. ft. assembly & finishes facility
• Specialization in formed aluminum structural components
• Full repertoire of CNC machining equipment
• FAA PMA Quality System
• Full service engineering to fabricated or manufactured part
AIRCORPS AVIATIONThe AirCorps fabrication team specializes in the use of traditional and state-of-the-art methods to manufacture and produce aircraft parts. Our adherence to the FAA-PMA Quality System, range of capabilities, and exacting detail are evident in the award-winning work for which AirCorps is known.
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C A PA B I L I T I E SREVERSE ENGINEERING
CAD/CAM PART DESIGN
METAL FORMING
• Portable handheld 3D laser scanning
• Highly accurate part measurement
• 3D scan to 3D CAD model creation
• Conversion of 2D drawings to 3D models
• Expertise in complex aircraft drawings & assemblies
• Design & engineering of tooling for fabrication
• Specialize in fabrication of forming aluminum structural components
• Equipment includes hydro-press, drop-hammer & stretch form table
• In-house tooling design & fabrication
• 3, 4 & 5 axis CNC machining
• 4 axis CNC lathe
• CNC router
CNC MACHINING
• Fully capable of manufacturing simple or complex assemblies
• Utilize custom developed software to manage large Bill of Materials & assemblies
• PMA quality control & inspection system
• Fixed CAD model design & engineering
• Fabrication & assembly of fixtures
• Full-scope services from small part to entire aircraft
• In-house aluminum heat treating
• Managed processes for anodizing, coating, polishings & platings
• In-house painting to spec
• In-house welding including TIG & aluminum spot -welding
E X P E R T I S EExperienced team producing par ts under an approved FAA-PMA qual i ty control sys tem. Our divers i ty of c l ients and world-c lass res torat ions have guided our comprehensive unders tanding of par ts fabricat ion.
Q U O T I N GOur team can quickly provide a quote and t imel ine for product ion of par ts drawing based on our years of experience at no cost .
P R O D U C T I O NBy internal ly managing the processing of manufactured par ts ever yday we can del iver customers precise, high-qual i ty par ts quickly and ef f ic ient ly.
T H E B E N E F I T S
ASSEMBLY & INSPECTION
FIXTURES & JIGS
VALUE ADDED SERVICES
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FABR ICATEDPARTS• AirCorps Aviation has fabricated thousands of different parts. Because our
team assembles, installs, and fits our fabricated parts we have an intimate
knowledge of what works and what doesn’t. We deliver parts organized and
labeled professionally that integrate seamlessly into a shop setting.
• Our team embraces, studies and perfects manufacturing techniques used
on prior generations of aircraft and by vendors not in business today.
The AirCorps team of fabricators will accurately reproduce challenging
obsolete parts while balancing the cost and efficiency afforded by modern
technologies.
• Client relationships are rooted in our knowledge of being both an world
class restorer of aircraft, consumer, and by supporting outside customers.
Our interactions are relationship driven, long-term, and valued.
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SHROUDFabricat ion Process: Hydro Press
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TORQUE T UBE BRAC KETFabricat ion Process: Hydro Press
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HORIZON TAL STABILIZER RIBFabricat ion Process: Hydro Press
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BU L KHEAD - REAR SEC T ION SPIN N ERFabricat ion Process: Metal Spinning, CNC Machining, Hydro Press
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EXH AUST BAFFLEFabricat ion Process: Drop Hammer
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ELEVATOR AT TAC H MEN T ARMFabricat ion Process: CNC Machining
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PLAT E - AN T EN N A RELAY UN ITFabricat ion Process: Press Brake
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BRAC KET - SH IELD ASSEMBLYFabricat ion Process: Press Brake
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WIN G SPAR FIT T IN GManaged Fabricat ion Process: Forging
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WIN G SPAR FIT T IN GManaged Fabricat ion Process: CNC Machining
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AN T EN N A MOUN T PLAT EFabricat ion Process: CNC Machining
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HOUSIN G - RET RAC T IN G LEVEL LUGFabricat ion Process: CNC Machining
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L A NDIN G GEAR PN UEMAT IC C OMPON EN TFabricat ion Process: CNC Machining
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AC C ESS D OORFabricat ion Process: CNC Machining
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C LEVIS - LAN D IN G GEAR D OORFabricat ion Process: CNC Machining
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LAN D IN G GEAR PLAT E - BRAKEFabricat ion Process: CNC Machining
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EN GIN E ISOLAT ION MOUN TFabricat ion Process: CNC Machining
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D OOR HIN GEFabricat ion Process: CNC Machining
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T H READ ED ROD EN DFabricat ion Process: CNC Machining
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TAN K FILLER D OOR PAN ELFabricat ion Process: Hydro Press
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HYD RAULIC C OMPON EN TFabricat ion Process: CNC Machining
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P- 47 T H UN D ERBOLT FUSELAGE ASSEMBLY
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F O R M E D A L U MIN UM ST RUC T URAL C OMPON EN T SFabricat ion Process: Hydro Press
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F O R M E D A L U MIN UM ST RUC T URAL C OMPON EN T SFabricat ion Process: Hydro Press
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ST RETC H FORMIN G
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ST RETC H FORMIN G
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METAL FORMING CNC MACHININGPROCESSES:
• Hydro-Press ing Sheet Metal Par ts
• Stre tch / Shrink Forming
• Brake Forming
• CNC Router ing F lat Pat terns
• Design to Fab Complex Tool ing Forms
PROCESSES:
• High qual i ty, repeatable machining
• High to lerance resul ts
• Low to Medium volume
• Mil l ing and turning varie ty of mater ia l types
E Q U I P M E N T D E TA I L S
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SHEET METAL ST RETC H ER TABLE250 Ton - 102” x 70” Capaci ty
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C N C PRESS BRAKE6 Foot, 35 Ton
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5 70 & 1 500 TON PRESS24” X 34” & 30” X 72” Rubber Pad Boxes
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C EC OSTAMP D ROP HAMMER32” X 32” Table
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DI GITAL C ON T ROL HEAT T REAT OVEN S24” x 18” x 43” & 60” x 60” x 60”
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H AAS 5 - AXIS C N C VERT IC AL MILL XYZ: 30” x 20” x 20”
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H AAS 4 - AXIS C N C LAT H E 10” Diameter & 20” Length
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H AAS 3 - AXIS C N C VERT IC AL MILLXYZ: 30” x 16” x 20”
H AAS 3 - AXIS C N C VERT IC AL MILL XYZ: 40” x 20” x 25”
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C N C ROUT ER TABLE4’ x 10’ table
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EN GIN E LAT HE15” Diameter - 48” Length
EN GIN E LAT HE15” Diameter - 48” Length
C N C C H UC KER LAT HE6” Diameter - 6” Length
BRID GEPORT MILLXYZ: 36” x 13” x 20”
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ALUMIN UM SPOT - WELD IN GSciaky 90KVA Mil -spec3/16 2024-T3 Capaci ty
T IG WELD IN GFerrous & Non-Ferrous AWS D17.1300 Amp Mil ler Aerowave
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PMA HOLDER NO. PQ04274CE
A D D I T I O N A L S E R V I C E S• Exper t ise in aerospace CAD
• Tool ing CAD Design & Fabricat ion
• Legacy 2D drawing to 3D CAD convers ion
• Reverse Engineering par ts thru s tate-of- the-ar t por table hand-held 3D laser scanning
• Engineering, CAD and fabricat ion of machining, assembly or inspect ion f ix tures
• Paint ing - f in ishes
• Metrology grade CMM inspect ions
• CAD f i le to par t inspect ion repor ts
• FAA PMA Qual i ty Program
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C AD : SOLIDWORKS 201 8
C AM: C AMWORKS 201 8
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F1 ROC KET EMPEN N AGE
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P- 47D T HUN D ERBOLTSol idworks: 7286 Par t F i les - 1818 Assemblies
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PORTABLE 3D LASER SC AN N IN GCreaform HandyScan & VXModel sof tware
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P- 47D FUSELAGE F IXT URE
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P- 51 D WIN G FIXT URE
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IN - H OUSE PAIN T BOOT H
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H EXAGON T IGO SF C MMXYZ: 20” x 23” x 20”Hexagon PC-DMIS sof tware
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FAA REPAIR STAT IONAPPROVAL, LAT E 201 8
PMA HO L DE R NO . PQ 0 4274CE
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C-47A SKYTRAIN “THAT’S ALL BROTHER”500+ Douglas Factory Markings, Paint Scheme Design, Insignia & Radio Call, Rubber Stamps, Paint Masks
ART SERV ICES
T HE M AT E R IALS WE USE
• Aluminum• Brass• Stainless Steel• Steel
• Phenolic• Acetate• Rubber Stamps• Vinyl
CU S TOM M ADE PLACA RD S, D ECA LS & NAME PLATES
• Etching• Engraving• Laser Cutting• Screen Printing
• Water Transfers• Stencils• Masks• Rubber Stamps• Metal Stamps
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WORLD CLASS QUAL I TY
Our award winning services have earned us numerous awards from AirVenture since 2011. We use our knowledge, experience and expert technique to produce the highest quality product. From fabricated replacement parts to PMA’d manufactured parts, we offer a full range of services required for the legacy and modern aircraft industry.
P-51C Lope’s Hope 3rd a 2018 AirCorps Aviation restoration
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For more information please contact:
STEFAN HOKUF FABRICATION SALES SPECIALIST
s tefanh@aircorpsaviat ion.com218.444.4478 Ex:121
1259 Exchange Ave SEBemidj i , MN 56601
www.aircorpsaviat ion.com
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www.aircorpsaviat ion.com